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Before You Start a DIY Kigurumi Mask

A DIY Kigurumi Mask is an advanced prop project, not usually the simplest or cheapest first route into the hobby. It combines 3d modeling, 3d printing, surface finishing, painting, eye construction, wig making and styling, and more.

It's worth understanding the full job, practising unfamiliar skills, and budgeting for iteration before committing to actually printing a mask and starting the build.

Honestly if you haven't seen a kigurumi mask in person before, there probably are a number of small details that you may not have considered regarding vision, facial detail design, and overall proper fit.

Skills a build can require​

Depending on the model and construction method, the work may include:

  • 3D modeling or modifying an existing model
  • measuring your head, eye positioning, and making sure the shell will both fit and be easy for you to see through
  • preparing a large print for a service or operating a suitable printer
  • joining, reinforcing, sanding, filling, priming, and painting a shell
  • designing and fabricating eyes
  • constructing and styling hair larger than a standard human wig in both size and volume of hair required
  • installing padding, latches or other closures
  • testing visibility, ventilation, balance

You can outsource modeling or printing, but outsourced parts still need to fit together and be finished. If several of these processes are new, practice them on smaller props, and inexpensive wigs first.

Cost and time​

DIY can save money but you honestly usually end up paying in time, and revisions. Other costs can include:

  • model or software costs
  • printing, shipping, or failed-print costs
  • filler, primer, paint, clear coat, adhesives, abrasives, and applicators
  • eye mesh or lenses, wig fibre, fasteners, foam, and electronics
  • respirators, filters, ventilation, gloves, and eye protection
  • replacement materials for test pieces and revisions

Plan for mistakes. The first printed shell, paint mix, eye design, or wig layout may not be the version you keep. Test painting processes before you commit to using them on your mask, and just because a shell is the first thing you print doesn't mean it's the best one you can make, nor necessarily the right fit for you. Revisions are inevitable and should be expected rather than an exception.

Printing considerations​

Kigurumi Mask shells are large. A printer that handles small models may not have the build volume, temperature control, reliability, or material capability required for a wearable shell.

FDM and resin printing can both work, with different equipment, joining, finishing, ventilation, and material requirements. Just because you have a printer accessible to you though, doesn't mean its the right one for the job.

PLA can deform in high heat, including a closed vehicle. Resin properties vary widely in structural integrity. ABS and ASA introduce ventilation and temperature-control requirements.

Fit, visibility, and hair​

A model that fits someone else may not fit you, even if it physically fits around your head. Particularly the view ports should be considered if they'll work, you can always pad the inside of a shell if needed, but a mask thats too small or cant align properly with your eyes is going to be a pain to use.

Standard wigs are made for human heads and may not provide enough coverage or fibre for a larger shell. Building up wefts, combining wigs, or using hard hair can require substantial planning and practice.

Whenever possible, study finished masks in person and ask experienced builders how functional details are arranged. Social photos may hide the underside, interior, eyeports, closures, and hair attachment.

Safety​

When sanding and painting do so in a well ventilated area, and wear the appropriate protective equipment. Your health and safety should always be a priority.

Choosing your route​

Commissioning is usually the strongest first option if your main goal is to wear a finished character. DIY makes more sense when learning and controlling the build are part of the goal and you can accept the cost of practice and revision.

Ready to investigate a build? Continue to the open-source Kigurumi Mask models and resources. If you would rather compare finished work, use the Kigurumi Mask maker directory.